CASE STUDY: From Failure to Excellence - Suspended Ceiling Replacement at a Lincolnshire MOD Site
- Ross Grant
- Apr 3
- 3 min read
In early 2025, Grant Ceilings & Interiors Ltd. was called upon to tackle an urgent suspended ceiling failure at a secure government facility in Lincolnshire. The issue, initially identified as a localised collapse, quickly evolved into a full ceiling replacement project — one requiring both technical precision and logistical coordination in a live, high-security environment.
This case study explores how we responded to the challenge, identified the root causes of failure, and delivered a modern, compliant, and high-performance suspended ceiling system.
Project completed March 2025. Specific location and client details withheld for privacy and security.
🛠️ The Initial Challenge: Urgent Call-Out & Safety Concerns
In February 2025, we received a request from a longstanding construction partner to assess a ceiling collapse in a 28-year-old building. The failure had occurred due to snapped wire hangers, causing part of the suspended ceiling to drop unexpectedly. With insulation and multiple light fittings sitting above the grid, safety was a critical concern.
The affected space was immediately sealed off, and Grant Ceilings & Interiors attended the site within days to carry out a full assessment.
🔍 Diagnosing the Problem
Our inspection found several contributing factors:
Over-fatigued wire supports from the original installation
Excessive load from 200mm insulation quilt and multiple light fittings
Possible legacy damage from previous maintenance access
We implemented a temporary stabilisation repair to ensure immediate safety. However, due to the age of the system and the unknown condition of adjacent areas, we advised a full ceiling replacement.
Before: Damaged ceiling with snapped wire hangers and insulation load issues.
After: New suspended ceiling system with Rockfon Artic tiles and 24mm grid.
📐 Scope of Work: From Stabilisation to Full Suspended Ceiling Replacement
✅ Phase 1 – Immediate Repair
We replaced the failed wire hangers and secured the grid to ensure the area was safe for investigation and planning.
✅ Phase 2 – Suspended Ceiling Replacement
The full works involved:
Removal of the existing 182 m² suspended ceiling
Installation of a new system using:
600x600mm Rockfon Artic acoustic ceiling tiles
24mm Chicago Metallic T24 grid
200mm mineral wool insulation quilt
Integration of perimeter trims, shadow battens, and custom window cheeks and heads
The replacement was designed to meet British Standards (BS EN 13964) and applicable thermal, acoustic, and fire performance regulations.
🔧 Challenges & Solutions
1. Urgency & Site Access
We responded within 72 hours, working around active building use and security requirements, using a scaffold tower and clear safety protocols.
2. Age-Related Concerns
The end client initially believed the ceiling had reached "end of life." We provided clear, technical reassurance that targeted issues — not age alone — were to blame, and that the new system would offer reliable long-term performance.
3. Fire Detection Delays
A late-stage query around fire detection in the ceiling void had the potential to delay installation. By working alongside the electrical contractor and other trades, we coordinated our start to avoid disruption to the programme.
4. Uncertain Window Details
The complex sloped and cheeked window reveals presented an unknown during planning. We flagged this early, allowing the client to build in flexibility and avoid delays.
📊 Design for Performance
The suspended ceiling replacement was designed for a total load capacity of 5.2 kg/m², with:
Tiles and grid: approx. 2.0 kg/m²
Insulation: approx. 1.73 kg/m²
Light fittings: independently supported, not hung from the ceiling grid
This ensured safety, longevity, and compliance with thermal and acoustic targets.
✅ The Outcome: Safe, Compliant, and Built to Last
Before: Aged ceiling nearing end-of-life, no longer fit for purpose.
After: Fully compliant, acoustically efficient ceiling in a secure MOD facility.
The project was completed in March 2025. The result:
A visually clean and modern ceiling using Rockfon Artic tiles
Improved thermal efficiency and acoustic comfort
Full compliance with MOD site requirements and British Standards
Minimal disruption to site operations or programme milestones
💬 Client Feedback & Lasting Value
Our client appreciated the swift response, detailed design approach, and open communication throughout the project. Concerns about potential future failures were addressed with practical, technically sound advice, including reassurance that a well-maintained suspended ceiling can exceed 30–50 years of use.
🧩 Key Takeaways
✅ Rapid mobilisation following a ceiling collapse
✅ Temporary repair followed by full replacement
✅ Design-led approach with safety, acoustic, and fire performance at its core
✅ Clear communication and technical support throughout
✅ Successful delivery in a high-security, operational facility
📞 Need Trusted Ceiling Specialists for Your Commercial or Government Project?
Whether it’s a ceiling replacement, partitioning system, or acoustic solution, we’re here to help.
📧 Email: info@grantceilings.co.uk
📞 Call: 01733 795974
🌐 Visit: www.grantceilings.co.uk
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